DEPARTMENT OF PRODUCTION ENGINEERING

The food and beverage manufacturing sector in Edo State is an important part of Nigeria’s industrial economy but faces major inefficiencies, including spoilage, defects, and overproduction. Lean manufacturing, derived from the Toyota Production System, offers a structured approach to eliminating waste and improving performance. Tools such as 5S, Kaizen, Just-in-Time (JIT), and Total Productive Maintenance (TPM) have proven effective in boosting productivity, although lean adoption in developing countries remains limited by infrastructural weaknesses, supply chain issues, and resistance to change. This study evaluates the contribution of lean practices to waste reduction and operational efficiency in selected food and beverage firms in Edo State. A mixed-methods design was adopted, using descriptive and analytical approaches. Data were obtained from 30 purposively selected firms through questionnaires, interviews, and direct observations. Descriptive statistics were used to categorize waste types, while regression and correlation analyses assessed the relationship between lean practices and waste reduction. Thematic analysis further examined barriers to implementation, and SPSS with Microsoft Excel ensured accurate data analysis. Findings indicated that spoilage was the most widespread form of waste, followed by defects and overproduction. Lean practices, especially 5S and JIT, significantly improved waste reduction, accounting for 67% of the variation in performance. However, unstable electricity supply, insufficient employee training, and unreliable suppliers weakened overall lean adoption. The study recommends a gradual implementation of lean, starting with easier-to-apply tools such as 5S and Kaizen, along with capacity-building programs and strengthened supply chain collaboration. Policy support for infrastructure and industry-focused training is essential to improve lean outcomes and support long-term sustainability.

This study aimed to evaluate and enhance the efficiency of a tile production facility in Benin City, Nigeria through MATLAB-based simulation and optimization. The research was conducted in response to persistent challenges in local tile manufacturing, including high energy consumption, low throughput, and significant defect rates. The study sought to develop a robust simulation model capable of analyzing the plant’s operational performance, identifying critical inefficiencies, and proposing optimization strategies that align with real-world production constraints. The methodology involved systematic data collection on machine utilization, downtime, energy consumption, and defect levels from the facility. These data were used to design a MATLAB simulation model that replicated the major stages of tile manufacturing mixing, pressing, drying, glazing, and firing. The model evaluated baseline performance conditions and tested multiple optimization scenarios such as load balancing, batch size adjustment, and preventive maintenance scheduling. The simulation outputs were analyzed to determine their operational feasibility within existing equipment and workforce limitations. The results showed substantial improvements across key production metrics. Daily output increased by approximately 20%, machine utilization rose from 85% to 92%, and defect rates decreased from 6.0% to 3.5%. Energy consumption per tile dropped by 7%, contributing to a 4.8% reduction in production cost. Financial projections indicated a 37% increase in monthly gross profit following optimization. These findings confirm that MATLAB simulation provides a cost-effective and practical approach for improving efficiency, product quality, and profitability in Nigeria’s tile manufacturing sector

Nigeria's unreliable power supply is a well-documented challenge that creates one of the most difficult business environments globally, undermining the country's competitiveness. The consequences are evident. To cope with the erratic electricity supply, individuals and businesses are forced to resort to expensive self-generated power solutions. One of ths Business adversely affected by the state of Power Generation and Distribution in Nigeria is the manufacturing industry. Most welders rely on the epileptic nature of power to carry out their jobs and meet consumer demands. In most instances, the business loss the goodwill/confidence of her customers as job completion schedules are not met. This project focuses on the design, development, and optimization of an inverter-based arc welding system. This work aims at helping small scale Welders Busneses Meet their need for power. Inveter Welding Systems can be deployed in rural and semi urban areas that are off-grid. With this improvement, skilled workers can carry out their job near the target use location with minimal transportation cost. With proper funding, this project can be expanded for large industial use. The optimized system demonstrates potential for applications in various industries, including automotive, aerospace, and construction

This project focuses on creating an eco-friendly and energy-efficient transportation option for urban areas. The main objective is to develop a solar-powered tricycle that leverages renewable energy to lower the carbon emissions typically associated with traditional urban transport. The tricycle is equipped with a high-efficiency AC motor powered by energy collected from a solar panel system on the vehicle. The design prioritizes optimal energy use, enhanced efficiency, and the capability to meet urban commuting demands. Key elements of the project include a solar panel array, a power distribution controller for effective energy management, and a durable battery storage system for energy reserves. The AC motor is chosen for its reliability and effective performance at low speeds, providing a smooth and stable ride. Furthermore, the tricycle features a lightweight and user-friendly design to improve comfort and maneuverability in busy urban environments. This initiative presents a novel solution for sustainable urban mobility, serving as a clean alternative to conventional vehicles. It seeks to help mitigate air pollution, reduce reliance on fossil fuels, and encourage the integration of solar energy in transportation. The final tricycle will exemplify the feasibility of solar-powered mobility options in contemporary cities, marking a significant advancement toward green and sustainable urban transportation

Efficient water management is essential for both domestic and industrial applications, particularly in regions where water scarcity and irregular supply are prevalent. This study presents the design and development of an automatic water pump controller system aimed at optimizing water usage and preventing wastage caused by overflow and dry running of pumps. The system is designed to automatically monitor water levels in storage tanks and control the operation of the pump without the need for human intervention.
The controller integrates sensors for water level detection, a control unit for signal processing, and a switching mechanism to activate or deactivate the pump based on predefined thresholds. When the water level in the tank falls below a minimum level, the system automatically switches on the pump, and it switches off the pump once the tank is full. Additionally, protective features such as dry-run protection and power fluctuation safeguards are incorporated to enhance system reliability and extend pump lifespan.
The prototype was constructed using cost-effective and locally available components and was tested under different operating conditions. Results demonstrate that the system effectively maintains desired water levels, reduces energy consumption, and minimizes water wastage. The developed automatic water pump controller provides a reliable, affordable, and user-friendly solution for improving water management in households and small-scale facilities

Yam (Dioscorea spp.) remains a major staple and economic crop in Nigeria, where it serves as a vital source of food and income. However, traditional yam processing methods involving manual pounding are time-consuming, labor-intensive, and unhygienic, making them unsuitable for large-scale or commercial production. This study focuses on the design, fabrication, and performance evaluation of an automated yam blending machine with an emphasis on minimizing material leakage—a common limitation in existing models. The machine was designed using mechanical and food engineering principles to achieve efficient blending through an electrically powered motor, stainless-steel blending chamber, and an effective sealing system that prevents leakage. Locally sourced materials were used to enhance affordability and promote indigenous technology. Performance evaluation showed that the machine successfully pounded 500 g of boiled yam within an average of 2.7 minutes, achieving an output efficiency of 97% and a throughput capacity of 16.18 kg/hr

Poultry farming is a crucial agricultural sector that provides protein and economic opportunities, particularly in rural communities. However, small-scale poultry farmers often face challenges in egg incubation due to unreliable electricity and the high costs of conventional incubators. This study explores the design, fabrication, and evaluation of a solar-powered egg incubator tailored for small-scale poultry farmers. The proposed incubator harnesses renewable solar energy to maintain optimal incubation conditions, ensuring stable temperature, humidity, and automated egg turning. The research employs a systematic approach, including component selection, design calculations, computer-aided design (CAD) simulations, and prototype fabrication. The incubator is designed to be cost-effective, energy-efficient, and scalable, making it accessible to farmers in off-grid areas. Performance tests demonstrated that the incubator maintained an internal temperature range of 37–38°C, achieving a hatchability rate of 91% and a fertility rate of 95%. Computational
Fluid Dynamics (CFD) analysis validated its thermal efficiency and air circulation patterns. The results indicate that solar-powered incubation is a viable alternative to conventional methods, reducing dependency on fossil fuels while enhancing productivity. This study contributes to sustainable poultry farming by offering a practical, environmentally friendly, and economically viable solution for small-scale farmers. Further research is recommended to explore large-scale applications and the integration of automated control systems

This study investigates the simulation of the actual maximum stress in Tungsten Inert Gas (TIG) weldment using SIMUFACT Welding software. The research aimed to compare the simulated stress values with experimental results obtained in a controlled environment under varying process parameters such as current, voltage, and gas flow rate. During the design of experiment, twenty experimental runs was generated by the Central composite design and it was used to carry out TIG welding on mild steel plates. A universal testing machine was used to record the actual maximumm stress on the welded joint and recorded as experimental values. The data generated from the CCD matrix was then feed into an expert system (SIMUFACT 2024) which was used to carry out TIG welding simulations with its corresponding actual maximum stress recorded alongside as the SIMUFACT result.
Results from this study revealed that that increasing welding current reduces the maximum stress due to higher heat input and lower cooling rate, while voltage variation influences arc width and stress distribution. The actual maximum stress values from both datasets were analyzed and compared. The results revealed close agreement between experimental and simulated values, a fitted line plot was used to ascertain the degree of correlation between both results and a correlation coefficient of 0.98 was observed, indicating a very strong positive correlation degree between the experimental result and the SIMUFACT result. A time series plot was then used to compare if both data sets assumed the same trend. The SIMUFACT welding simulation analysis proved to be a reliable tool for simulating and predicting the actual maximum stress in TIG-welded joints thereby aiding in the optimization of welding parameters for an improved structural integrity.

Yam (Dioscorea spp.) remains a major staple and economic crop in Nigeria, where it serves asavital source of food and income. However, traditional yam processing methods involvingmanual pounding are time-consuming, labor-intensive, and unhygienic, making themunsuitableforlarge-scale or commercial production. This study focuses on the design, fabrication, andperformance evaluation of an automated yam blending machine with an emphasis on minimizingmaterial leakage—a common limitation in existing models. The machine was designed using mechanical and food engineering principles to achieveefficient blending through an electrically powered motor, stainless-steel blending chamber, andan effective sealing system that prevents leakage. Locally sourced materials were used to enhance affordability and promote indigenoustechnology. Performance evaluation showed that the machine successfully pounded 500gofboiled yam within an average of 2.7 minutes, achieving an output efficiency of 97%andathroughput capacity of 16.18 kg/hr. The pounded yam produced exhibited excellent textural qualities comparable to traditionallyprepared samples. The developed machine demonstrated improved hygiene, ease of operation, and significant reduction in processing time, thereby offering a viable solution for householdandsmall-scale commercial yam processing. This innovation contributes to Nigeria’s local equipment fabrication efforts and enhances food processing mechanization.

Welding is an essential fabrication process in various industries, including automotive, aerospace, shipbuilding, and construction. It is a method used to join metals or thermoplastics through coalescence, usually involving the application of heat or pressure. The welding of similar metals, such as steel-to-steel or aluminum-to-aluminum, is relatively well-understood, with established techniques and filler materials to ensure strong and reliable welds. However, welding dissimilar metals (those with different chemical compositions and physical properties) introduces additional challenges due to the inherent differences in melting points, thermal conductivity, and expansion rates.Dissimilar metal welding (DMW) has gained increasing attention in recent years due to its potential to optimize material properties in critical applications. For instance, in the automotive industry, lightweight materials like aluminum are welded to stronger metals such as steel to produce fuel-efficient vehicles without compromising safety. In the aerospace industry, DMW enables the combination of materials like titanium and aluminum, offering a balance between strength, heat resistance, and weight reduction.The role of filler materials is particularly important in DMW, as they act as intermediaries between the base metals, helping to form a stable joint. The choice of filler material influences not only the mechanical strength of the weld but also its resistance to corrosion, heat, and stress. Incompatible filler materials can lead to poor weld strength, the formation of brittle intermetallic compounds, or cracking. This study seeks to explore how different filler materials affect weld strength in DMW, with the ultimate goal of identifying the optimal materials for specific dissimilar metal combinations.